Duration
1 day
Overview
One of the greatest challenge to today's industries and companies is how to change eliminate or reduce waste in production.
Among the wastes is the Long Changeover during the production. Hence we need to find ways to eliminate or reduce the changeover time as much as possible. To achieve this, our employees must be well equipped with the right knowledge and ethod to work towards the appropriate process of changeover and simplification effectively.
A creative thinking in analyzing problem and deriving root causes is the key to SMED implementation success.
This session intends to explore the method and practical approach in achieving SMED through the total participation and involvement of employees.
Methodology: This Course will be conducted in Workshop Format where all participants need to work together to solve a technical problems provided using the techniques learnt from the course.
Objectives
After attending the course, participants should be able to:
- 1. Analyze a changeover situation in a more objective manner.
- 2. Apply relevant fast changeover techniques to solve root causes effectively.
- 3. Apply “Kaizen” approach in improving the changeover process.
- 4. Achieving ultimate goal of “Zero Changeover time” for relevant tools and dies.
Who should participate
This is a analytical session which is suitable for all technical professionals including technicians, engineers and managers and those whose daily job involve solving technical, machines or process changeover related problems.
Outline
- Introduction to “Zero Changeover”
- 7 wastes in a factory.
- What is “Zero Changeover”?
- Definition of “Zero Changeover”
- “Zero Changeover” for general dies, tools and jigs in industries.
Exercise on simple change over for molding machines.
- Steps towards “Zero Changeover”.
- Mindset removal regarding the possibilities of changeover.
- Management support and leadership requirements
- Methods of recording changeover data, video, diagram and observations.
- Changeover Process mapping
- Analysis of process waste.
- Develop actions to reduce or eliminate wastes.
- Horizontal deployment.
Exercise : Mindset removal for achieving “Zero Changeover”
- Formula for achieving “Zero Changeover”.
- Eliminate setup waste
- Eliminate replacement waste
- Eliminate adjustment waste.
Case studies and exercise : Application of above principles in your selected machine.
- Changeover for processing industries.
- Eliminating changeover waste in processing industries.
- Multi-process horizontal handling of machines
- U-shaped cell design for manufacturing process.
Example of processing line changeover improvement..
- Inexpensive changeover improvement to reduce employee’s needs.
- Which comes first: Changeover improvement or new line layout?
- Building better process line with lower cost.
- Parallel machine lines.
Examples and exercises : Reduce labor on automated process/robot line.
- 6. Steps for improving new process lines.
- The TPS method of line improvement.
- P-Q analysis of current production system.
- Simplified methods.
Exercise: Test your skills in improving changeover time and improvement of productivity through
setup time reduction.
- Discussion and Q & A.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.